Solar Control Coating for Glass via Aerosol CVD
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Solution Overview
Problem
Existing glass coatings for solar control in architectural and automotive applications fail to effectively block infrared radiation while maintaining high visible transmittance, mechanical strength, chemical resistance, and weather resistance, and are complex to develop due to the need for neutral color, low dispersion, and cost-effectiveness.
Innovation Solution
A coating composed of multiple layers of metal oxide semiconductors (TiO2, ZnO, ZrO2, Al2O3) with a layer of metal nanoparticles (Au, Ag) deposited using the aerosol-assisted chemical vapor deposition technique, which creates a Schottky junction for oxidation protection and IR blocking, while ensuring high visible transmittance and mechanical strength.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If conventional glass coatings are used to block infrared radiation, then solar control performance is improved, but visible transmittance and mechanical strength are compromised
Solution Approach 1:
The patent applies composite materials by combining multiple metal oxide layers (TiO2, ZnO, ZrO2, Al2O3) with different refractive indices and optical properties to create a coating that simultaneously blocks infrared radiation and maintains visible transmittance and mechanical strength. The synergistic effect of these composite layers allows achieving solar control performance without sacrificing structural integrity or optical clarity.
Solution Approach 2:
The coating is segmented into multiple thin layers of different metal oxides, each contributing specific optical and mechanical properties. This segmentation allows independent optimization of infrared blocking, visible transmittance, and mechanical strength through careful selection and thickness control of each layer, resolving the contradiction between these competing requirements.
2Object-affected harmful factors
If multiple coating layers are added to improve solar control properties, then infrared blocking is enhanced, but coating complexity and manufacturing difficulty increase
Solution Approach 1:
The complex solar control function is segmented across multiple simpler metal oxide layers, each with specific optical properties. This segmentation allows the complex infrared blocking to be achieved through the combined effect of simpler individual layers, making the manufacturing process more controllable and less complex than using a single complex material.
Solution Approach 2:
The patent utilizes parameter changes in refractive index, layer thickness, and material composition to optimize the coating performance. By carefully adjusting these parameters across the different metal oxide layers, the coating achieves enhanced infrared blocking while maintaining manageable manufacturing complexity through systematic parameter optimization rather than requiring complex structural designs.
3Object-affected harmful factors
If metal nanoparticles are deposited to enhance IR blocking, then solar control performance is improved, but oxidation and agglomeration of nanoparticles occur
Solution Approach 1:
The patent uses metal oxide layers as intermediary protective barriers between the metal nanoparticles and the external environment. These intermediary oxide layers prevent direct exposure of the nanoparticles to oxidizing conditions, thereby preventing oxidation and agglomeration while allowing the nanoparticles to maintain their infrared blocking function. The metal oxide layers act as a protective mediator that preserves nanoparticle stability.
Solution Approach 2:
The coating structure combines metal nanoparticles with metal oxide layers to create a composite material system where the oxide layers provide protective functions while the metal nanoparticles provide infrared blocking. This composite structure ensures nanoparticle stability by embedding them within or alongside the protective oxide matrix, preventing degradation while maintaining optical performance.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The coating achieves significant infrared blocking with high visible transmittance, mechanical, thermal, and chemical resistance, passing industrial tempering and laminating tests, and maintaining solar control performance through uniform nanoparticle distribution and active semiconductor layers.
Implementation Method 1
deposited using the aerosol-assisted chemical vapor deposition technique
Implementation Method 2
creates a Schottky junction for oxidation protection and IR blocking
Implementation Method 3
significant infrared blocking
Implementation Method 4
Solar control refers to the ability to change the amount of transmitted or reflected radiation, in the near-UV (UV; 300-380 nm), visible (VIS; 380-780 nm) and infrared (IR; 780-2500 nm) spectral ranges
Data Source
AI summary
The present invention relates to coating glass for architectural or automotive use, either monolithic or laminated, having solar control properties. The coating consists of several layers of different metal oxide semiconductors (TiO2, ZnO, ZrO2, SnO2, Al2O3) and a layer of metallic nanoparticles, which when superimposed on a pre-established order give the glass solar control properties. In particular the use of protective layers of n-type semiconductors around the metallic nanoparticles layer. It also relates to the method for obtaining the coating by means of the aerosol-assisted chemical vapor deposition technique, using precursor solutions containing an organic or inorganic salt (acetates, acetylacetonates, halides, nitrates) of the applicable elements and an appropriate solvent (water, alcohol, acetone, acetylacetone, etc.). The synthesis is performed at a temperature between 100 and 600° C. depending on the material to be deposited. A nebulizer converts the precursor solution into an aerosol which is submitted with a gas to the substrate surface, where due to the temperature the thermal decomposition of the precursor occurs and the deposition of each layer of the coating occurs.